Tuesday, May 29, 2012

Covers all U.S. and Canadian models of the Dodge Ram 1500, 2500, 3500, 2WD & 4WD From year 2001 to 2005.

Fuel Rail (Supply Manifold) & Injectors
REMOVAL & INSTALLATION

3.7L Engine

CAUTION

The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.

WARNING

The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tubes. Due to design of tubes, it does not use any clamps. Never attempt to install a clamping device of any kind to tubes. When removing fuel rail assembly for any reason, be careful not to bend or kink tubes.

Remove fuel tank filler tube cap.

Properly relieve the fuel system pressure, as outlined in this section.

Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.

Remove fuel rail (with injectors attached) from engine.

If fuel injectors are to be removed, refer to the Fuel Injector Removal & Installation procedure in this section.

To install:

If fuel injectors are to be installed, refer to the Fuel Injector Removal & Installation procedure in this section.

Clean out fuel injector machined bores in intake manifold.

Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.

Guide each injector into cylinder head. Be careful not to tear injector O-rings.

Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bottomed on cylinder head shoulder.

Install 4 fuel rail mounting bolts and tighten.

Install 6 ignition coils.

Connect electrical connectors to throttle body.

Connect electrical connectors at all fuel injectors. To install connector, push connector onto injector and then push and lock red colored slider. Make sure the connector is locked to the injector by lightly tugging on connector.

The fuel system is under a constant pressure (even with engine turned off). Before servicing fuel rail assembly, fuel system pressure must be released.

WARNING

The left and right fuel rails are replaced as an assembly. Do not attempt to separate the rail halves at the connecting hose. Due to the design of this connecting hose, it does use any clamps. Never attempt to install a clamping device of any kind to the hose. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose.

For 3.9L engines, disconnect electrical connector at intake manifold air temperature sensor. Do not remove sensor.

Disconnect fuel tube (line) at side of fuel rail. Refer to Quick-Connect Fittings for procedures,

Remove the remaining fuel rail mounting bolts.

Gently rock and pull the left fuel rail until the fuel injectors just start to clear the intake manifold. Gently rock and pull the right fuel rail until the fuel injectors just start to clear the intake manifold. Repeat this procedure (left/right) until all fuel injectors have cleared the intake manifold.

Remove fuel rail (with injectors attached) from engine.

Remove the clip(s) retaining the injector(s) to fuel rail.

To install:

Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.

Install injector(s) and injector clip(s) to fuel rail.

Position the fuel rail/fuel injector assembly to the injector openings on the intake manifold.

Guide each injector into the intake manifold. Be careful not to tear the injector O-ring.

Push the right fuel rail down until fuel injectors have bottomed on injector shoulder. Push the left fuel rail down until fuel injectors have bottomed on injector shoulder.

The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.

WARNING

The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tubes. Due to design of tubes, it does not use any clamps. Never attempt to install a clamping device of any kind to tubes. When removing fuel rail assembly for any reason, be careful not to bend or kink tubes.

Remove fuel tank filler tube cap.

Properly relieve the fuel system pressure, as outlined in this section.

Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.

Remove fuel rail (with injectors attached) from engine.

If fuel injectors are to be removed, refer to the Fuel Injector Removal & Installation procedure in this section.

To install:

If fuel injectors are to be installed, refer to the Fuel Injector Removal & Installation procedure in this section.

Clean out fuel injector machined bores in intake manifold.

Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.

Guide each injector into cylinder head. Be careful not to tear injector O-rings.

Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bottomed on cylinder head shoulder.

Install 4 fuel rail mounting bolts and tighten.

Install 8 ignition coils.

Connect electrical connectors to throttle body.

Connect electrical connectors at all fuel injectors. To install connector, push connector onto injector and then push and lock red colored slider. Make sure the connector is locked to the injector by lightly tugging on connector.

The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.

WARNING

The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tube. Due to design of tube, it does not use any clamps. Never attempt to install a clamping device of any kind to tube. When removing fuel rail assembly for any reason, be careful not to bend or kink tube.

Remove fuel tank filler tube cap.

Properly relieve the fuel system pressure, as outlined in this section.

Remove negative battery cable at battery.

Remove flex tube (air cleaner housing to engine).

Remove air resonator box at throttle body.

Disconnect all spark plug cables from all spark plugs and ignition coils. Do not remove cables from cable routing tray. Note original cable positions while removing.

Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in intake manifold. Gently rock and pull right side of rail until injectors just start to clear intake manifold head holes.

Repeat this procedure (left/right) until all injectors have cleared machined holes.

Remove fuel rail (with injectors attached) from engine.

If fuel injectors are to be removed, refer to the Fuel Injector Removal & Installation procedure in this section.

To install:

If fuel injectors are to be installed, refer to the Fuel Injector Removal & Installation procedure in this section.

Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.

Attach the electrical connectors at all fuel injectors. To install connector, push connector onto injector and then push and lock red colored slider. Make sure the connector is locked to the injector by lightly tugging on connector.

Connect the fuel line latch clip and fuel line to fuel rail.

Install air resonator to throttle body (2 bolts).

Install flexible air duct to air box.

Connect battery cable to battery.

Start engine and check for leaks.

8.0L Engine

CAUTION

The fuel system is under a constant pressure even with the engine off. Before servicing fuel rail, fuel system pressure must be released.